Disposable foot care article and method of manufacture thereof

ABSTRACT

A disposable foot-care article in the form of a toe cover made of absorbent non-woven fabric or suituable stock, and method of manufacturing same that utilizes a continuous web wherein the web is impregnated with medicated foot-care agents, folded longitudinally into at least a partial overlap and then sealed and cut diagonally to produce a slipper-shaped toe cover.

United States Patent no Tundermann 1 1 [)ISIOSABLE FOOT (ARE ARTICLE ANDMETHOD OF MANUFACTURE THEREOF |75| inventor: Werner (l. Tundermann,(oloni-a.

|73| Assignee: Colgate-Palmolive Company, New

York. N.Yi

122] Filed: Oct. [5. I973 121 Appl No.; 406.297

152] [1.8. CI. .t lZ8/260; 128/81 R I51] Int. Cl v. Ablm 35/00; Afilm37/00 [581 Field of Search 128/260. 581, min. 166.5, 128/81 R; 15/227;2/61 239; 36/9 A 10 8.1; DIE/283 1561 References Cited UNI'I'ED STAIHSPATENTS LSZLQIS l/IU25 lilwcl 1. 15/227 1.544578 7/1925 Henderson 3M9 A211mm); 12/1936 Kcnagy. Sr. cl :1]. 36/9 A 1541272 2/1951 Iieman, Jr128/200 1451 May 13,1975

211011151 7/1952 Jones 128/260 162L784 12/1952 Vanlioytham .1 15/227 X1740,2117 4/1956 Starensicr 1 1 1 1 1 128/81 R 3,1X3 543 5/l9fi5Worcester. 15/227 X DI92 2I0 2/1962 Webster .1 D2/283 FORHKIN PATENTS ORAPPLICATIONS 971,054 6/1950 France 15/237 Primary l;'.raniim'rAldrich FYMcdhcry AHUIIM), Agt'nl. or I-'irm-Herhert S, Sylvester, Esq.; Murray M.(irill, Esq; Kenneth A. Koch. Esq

I571 ABSTRACT A disposable foot-care article in the form of a toe covermade of absorbent nonwoven fabric or suituahle stock, and method ofmanufacturing same that uti lizcs a continuous weh wherein the web isimpreg' nated with medicated foot-carc agents folded longitudinally intoat least a partial overlap and then sealed and cut diagonally to producea slipper-shaped toe ll Claims 6 Drawing Figures mgmgn MAY 1 3x975 3.882.868

CONTINUOUS WEB OF NON-WOVEN FABRIC OR PAPER IMPREGNATE WEB WITH 50ANTIMICROBIAL AND DEODORANT AGENTS F/GJ I2 HEAT SEAL FOLD WEB TO PARTIALOVERLAP DISPOSABLE FOOT CARE ARTICLE AND METHOD OF MANUFACTURE THEREOFBACKGROUND OF THE INVENTION 1. Field of the Invention This inventionrelates to a foot care toe cover and method of manufacture thereof thatis adapted to release deodorizing and antifungal agents or the like, andbe absorbent of perspiration.

The toe cover is manufactured from a continuous web that is impregnated,folded longitudinally, and heat sealed, or the like, and cut diagonallybefore being packaged. The toe cover is capable of rendering con tinuousmedication for extended periods of time and the method of manufacturingthe article is capable of highly efficient high speed operation,allowing the toe cover to be produced inexpensively.

2. Description of the Prior Art Various types of foot care devices andproducts have been employed in the past in the form of powders, creams,and sprays.

These products have a short time activity and can be inconvenient andmessy to apply.

Prior foot covering devices have been used such as shown in US. Pat.Nos. 1,637,285 and 3,299,894. These patents show foot coverings that areutilized as moisture absorbent appliances or as blister preventiveshields. The prior devices are shaped to fit the foot tightly and areelastic so the foot could be placed into the covering.

US. Pat. No. l,659,l7l shows a partial stocking shape device that isadapted to give the foot support by utilizing a plurality of layers. Thedevice must be shaped and dimensioned to fit the foot exactly so thelayers of stuffing can engage the foot and render support at the properlocation.

In the past, the devices were expensive to manufacture as they weredesigned to fit the foot exactly and were adapted to be used many times.The materials utilized were light woven fabrics so the devices could beflexible and durable.

It was difficult, utilizing the prior art, to have an inexpensive buteffective means of continuously treating a foot ailment.

SUMMARY OF THE INVENTION The present invention comprises a disposablefootcare toe cover, and a method of manufacturing same that overcomescertain disadvantages of the prior art, especially where continuousapplication of medication is desired. The presently to be disclosedinvention overcomes prior disadvantages of the art and provides benefitsby virtue of its composition, form, and low manufacturing cost.

In the present invention, the device is made of nonwoven material in theform of a partial slipper which covers the toes, and may be worn under asock or stocking during the day. The non-woven material helps to absorbfoot perspiration and acts as a carrier for medication such asfungicidal and deodorizing agents or the like, which may be held in theinterstices of the fibers or may be coated on the surface of the toecover in the form of moisture sensitive micro-capsules or molecularsieve powders.

It is therefore an object of this invention to provide for simple andnon-messy application of foot care medications. Further, to provide allday activity of the desired foot-care agents.

One feature of the present invention resides in the provision that thetoe cover lends itself to a rapid manufacturing method as set forthherein.

Another object of the invention is to provide a foot care device made ofa single sheet of material.

Another object of the present invention is the provision that acontinuous web can be impregnated by a dusting or spray-and-dry step, orthe like, followed by folding, bonding, and cutting in high speedproduction manner.

A still further object of the present invention is to provide a footcare means manufactured from a continuous web that is impregnated fromone side.

These objects and other features of the invention, which will becomeapparent as the following description proceeds, are attained by thisdisposable foot care article and method of manufacture thereof, apreferred embodiment of which are shown in the accompanying drawing byway of example only, wherein:

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a schematic representation ofthe continuous web as it proceeds through the steps of beingmanufactured into a foot-care article according to the concepts of thepresent invention;

FIG. 2 is a top plan view of a toe cover according to the concept of theinvention;

FIG. 3 is a vertical sectional view thereof, taken along the plane ofline 3-3 in FIG. 2;

FIG. 4 is a longitudinal sectional view thereof shown engaged on a foot;

FIG. 5 is a top plan view of the foot care article shown engaged on thefoot; and

FIG. 6 is a top plan view thereof shown packaged.

DETAILED DESCRIPTION OF THE INVENTION With continuing reference to theaccompanying drawing wherein like reference numerals designate similarparts throughout the various views, reference numeral 10 is used togenerally designate a disposable foot-care article in the form of a toecover constructed in accordance with the concepts of this invention.

The toe cover 10 is of one piece construction of nonwoven fabric, paper,or the like that is capable of being bonded or heat sealed, that can beeasily and inexpensively manufactured according to the concepts of thisinvention.

The article 10 includes a lower parallelogram-shaped sole portion 12. Atthe front edge of the sole is a diagonal fold 14 that defines the upperor last portion 16 which extends upwardly and rearwardly back over thefront portion of sole 12. The upper portion 16 is a parallelogram-shaped member somewhat shorter than sole 12 whereby sole 12 extendsrearwardly of the upper portion 16.

The fold 14 defines a line that is on an acute angle to a perpendicularof the longitudinal side edges of the sole portion 12. These foot carearticles for right and left feet can be easily produced by merely avariation in the aforesaid angle. The parallel side edges of portion 16and sole l2 coincide and are sealed together along the length of theircoexistence along parallel sealing paths 18, by heat, adhesives, or thelike.

The forward section of sole 12 and the upper portion 16 are fixedtogether on three sides, by fold 14 at the front and sealed portions ISon the sides, thereby defm ing a pocket open at the rear edge of upperportion l6. Pocket 20 is dimensioned such that it is adapted to receivethe foot of a user 22 by inserting the toes and forward section of thefoot 22, below portion 16 and on top of sole 12.

The upper surface of sole l2 and the lower surface of portion 16 areimpregnated with medicated foot care agents, 24 such as, but not limitedto, antimicrobial, fungicidal, and/or deodorant agents. Therefore, whena users foot 22 is inserted into pocket 20 the medication 24 engages thetoes and forward section of the foot 22.

The partial slipper form of the toe cover 10 surrounds the toes and maybe worn under a sock or stocking during the day. The non woven materialof the toe cover 10 may be a wet strength paper and helps to absorb footperspiration, thereby aiding foot comfort, and acts as a carrier forantifungal and deodorizing medication 24, or the like, which may be inthe interstices of the fibers or may be coated on the surface of the toecover 10 in the form of moisture sensitive microcapsules or molecularsieve powders.

Examples of the possible medicated agents 24 is an anti-fungal agentsuch as undecylenic acid recommended for athletes foot, a deodorantingredient and antibacterial agent such as trichloroQ-hydroxy diphcnylether and mild astringents such as zinc phenolsulfonate.

The toe cover 10 is of one piece construction and may be manufactured bya method utilizing a continuous web 50 of non-woven fabric or paper,capable of being bonded or heat sealed, or the like.

The method of manufacturing toe covers 10, as shown schematically inFIG. 1, utilizes a continuous web 50 of material that is created by apaper making or non-woven web making machine. Web 50 is then impregnated from one side with any desired foot care agents 24 that can beapplied by dusting or spray-anddry equipment, or the like. The web 50 isthen folded longitudinally to at least a partially overlapping positionwhereby the impregnated surfaces are facing each other. The longitudinalfold l4 creates an upper portion 16, and a longer sole portion 12 thatextends rear wardly of portion 16. The two portions 12 and 16 are bondedtogether along the length of their coexistence along parallel sealingpaths 18 that are on an acute angle to a perpendicular of the linedefined by the longitudinal fold 14. The portions 16 and I2 are bondedtogether by means of adhesives, heat sealing, or the like.

The impregnated, folded, and sealed web 50 is then completely cut on adiagonal to the folded edge 14. The cutting of web 50 takes place alonga line that exactly coincides with the center line of the sealing paths18. The sealing path 18 is sufficiently wide so that the portions 12 and16 are bonded together on either side of the cut positioned in thesealing path 18. Thus, after web 50 has been completely severed,creating toe cover article 10, the sole l2 and upper portion 16 arestill sealed together along the edges of their coexistence. It is to beunderstood that the heat sealing along the side edges and the cuttingstep may be accomplished simultaneously using a heated cutting blade.Toe covers 10 can be manufactured utilizing high speed impregnating,folding, sealing, and cutting equipment so that continuous sheet ofnon-woven fabric, or

the like, can be efficiently turned into uniform, low cost, disposablefoot-care toe covers,

Once severed from web 50, the covers 10 may be packaged, in anyquantity, in a suitable package 60.

The method of manufacturing toe covers as set forth is adapted such thatthere is no waste whatsoever of the web 50. Further, the web 50 isimpregnated on one side and then longitudinally folded so that theimpregnating agents are utilized and positioned only where they will behighly effective when toe cover 10 is placed on the foot lf separatearticles are to be made for right and left feet, the angularrelationship of parts can be determined for right and left feet andpairs of foot care articles can be packaged as desired.

A latitude of modification and change is intended in the foregoingdisclosure, and in some instances some features of the present inventionmay be employed without a corresponding use of other features.

l claim:

1. A disposable toe cover of non-woven material comprising a singlesheet impregnated with antimicrobial and deodorant agents on one surfacethereof, said sheet being folded to define a front edge with an upperportion and a lower sole portion having the impregnated surfaces facingeach other said upper por tion being continuous and coextensive withsaid sole portion, and said folded sheet having its side edges sealed toeach other, said side edges being defined by parallel straight lines,one of said side edges extending at an acute angle from said front edge,the other of said side edges extending at an obtuse angle from saidfront edge.

2. A disposable toe cover according to claim 1, wherein said material ispaper having moisture absorptive and wet strength properties.

3. A disposable toe cover according to claim 1, wherein said agents areselected from the group consisting of undecylenic acid, trichloro-2hydroxy di phenyl ether, and zinc phenosulfonate.

4. A disposable toe cover according to claim 1 wherein said upperportion is smaller than said sole portion so that said sole portionextends rearwardly of said upper portion.

5. A disposable toe cover according to claim 1 wherein said front edgeis defined by a substantially straight line.

6. A method of manufacturing foot care toe covers comprising the stepsof impregnating a continuous web of non-woven material with foot-careagents on one side thereof, folding said web longitudinally to at leasta partial overlap wherein said impregnated sides faces each other,sealing said overlapping portions along parallel sealing paths thatextend at an acute angle relative to a line perpendicular to said fold,and then transversely cutting the entire web along a line extendingwithin at least one of said sealing paths.

7. A method according to claim 6, wherein said sealing is a heat sealingstep.

8. A method according to claim 6, wherein said sealing is an adhesivesealing step.

9. A method according to claim 6, wherein said footcare agent isundecylenic acid.

10. A method according to claim 6, wherein said foot-care agent istrichloro-Z-hydroxy diphenyl ether.

11. A method according to claim 6, wherein said foot-care agent is zincphenolsulfonate.

1. A DISPOSABLE TOE COVER OF NON-WOVEN MATERIAL COMPRISING A SINGLESHEET IMPREGNATED WITH ANTI-MICROBIAL AND DEODORANT AGENTS ON ONESURFACE THEREOF, SAID SHEET BEING FOLDED TO DEFINE A FRONT EDGE WITH ANUPPER PORTION AND A LOWER SOLE PORTION HAING THE IMPREGNATED SURFACESFACING EACH OTHER SAID UPPER PORTION BEING CONTAINUOUS AND COEXTENSIVEWITH SAID SOLE PORTION, AND SAID FOLED SHEET HAING ITS SIDE EDGES SEALEDTO EACH OTHER, SAID SIDE-EDGES BEING DEFINED BY PARALLEL STRAIGHT LINES,ONE OF SAID SIDE EDGES ESTENDING AT AN ACUTE ANGLE FROM SAID FRONT EDGE,THEE OTHER OF SAID SIDE EDGES EXTENDING AT AN OBTUSE ANGLE FROM SAIDFRONT EDGE.
 2. A disposable toe cover according to claim 1, wherein saidmaterial is paper having moisture absorptive and wet strengthproperties.
 3. A disposable toe cover according to claim 1, wherein saidagents are selected from the group consisting of undecylenic acid,trichloro-2-hydroxy diphenyl ether, and zinc phenosulfonate.
 4. Adisposable toe cover according to claim 1 wherein said upper portion issmaller than said sole portion so that said sole portion extendsrearwardly of said upper portion.
 5. A disposable toe cover according toclaim 1 wherein said front edge is defined by a substantially straightline.
 6. A method of manufacturing foot care toe covers comprising thesteps of impregnating a continuous web of non-woven material withfoot-care agents on one side thereof, folding said web longitudinally toat least a partial overlap wherein said impregnated sides faces eachother, sealing said overlapping portions along parallel sealing pathsthat extend at an acute angle relative to a line perpendicular to saidfold, and then transversely cutting the entire web along a lineextending within at least one of said sealing paths.
 7. A methodaccording to claim 6, wherein said sealing is a heat sealing step.
 8. Amethod according to claim 6, wherein said sealing is an adhesive sealingstep.
 9. A method according to claim 6, wherein said foot-care agent isundecylenic acid.
 10. A method according to claim 6, wherein saidfoot-care agent is trichloro-2-hydroxy diphenyl ether.
 11. A methodaccording to claim 6, wherein said foot-care agent is zincphenolsulfonate.